Benchmark BG4000i User manual

BG4000i
USER MANUAL
TM

The engine exhaust from this product contains chemicals known to
cause cancer, birth defects or other reproductive harm.
©2021 Benchmark. All Rights Reserved.
BG4000I_UG_EN_2021-05-21
TM

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SAVE THESE INSTRUCTIONS
This user guide contains important instructions
covering the setup, safety, operation and maintenance
procedures that should be followed for the BG4000i.
All information in this publication is based on the latest
product information available at the time of print.
No part of this publication may be reproduced
without written permission.

TM
WARRANTY INFORMATION
Online: benchmark.midlandpowerinc.com
Email: [email protected]
Phone: [phone]
Warranty support, operation assistance and product support is
provided by Midland Power Inc., a licensed manufacturer of Benchmark
Generators. Please contact us directly for any warranty service questions.
See ‘Limited Warranty’ for more information.
Product registration is required for product support and warranty
coverage. You can register online at benchmark.midlandpowerinc.com.
Once your registration is complete, your receipt will be on file and any
future warranty claims will be easily created.

BG i-SERIES
TABLE OF CONTENTS
1. Safety 1
2. Learn About Your Generator 5
2.1 Component Identification 5
2.2 Control Panel 6
2.3 Control Functions 7
2.4 Make Sure You Have Everything 8
3. Pre-Operation Check 9
3.1 Add oil 9
3.2 Add fuel 11
3.3 Check the Air Filter 12
4. Starting the Engine 13
4.1 Starting Your Generator 14
5. Generator Use 16
5.1 Ready to Use, Overload, and Oil Alert Indicator 16
5.2 DC Applications 17
5.3 AC Applications 18
6. Stopping the Engine 19
7. Maintenance 20
7.1 Maintenance Schedule 21
7.2 Changing the Oil 22
7.3 Cleaning the Air Filter 24
7.4 Spark Plug Maintenance 25
7.5 Spark Arrester Maintenance 26
7.6 Fuel Filter Maintenance 26
7.7 Valve Clearance 27
7.8 Emission Control System 28
8. Transportation & Storage 30
9. Troubleshooting 32
10. Technical Specifications 34
11. Wiring Diagram 35
12. Appendix 36
13. Limited Warranty 37

1
1. SAFETY
DANGER!
Using a generator indoors can kill you in minutes.
Generator exhaust contains carbon monoxide. This is a poison
that you cannot see or smell.
NEVER use inside a home or garage.
WARNING!
This product can expose you to chemicals including carbon
monoxide, which is known to the State of California to cause
cancer and birth defects or other reproductive harm. For more
information go to www.P65Warnings.ca.gov
1.1 OPERATOR SAFETY
WARNING!
Always perform an oil, fuel and air lter check before starting the engine.
Properly clean and maintain the equipment.
Operate the generator according to instructions for safe and
dependable service.
Before operating the generator, read the user guide carefully. Otherwise,
personal injuries or equipment damage may result.
Never run the generator in an enclosed area to avoid harm from exhaust
emissions of a poisonous carbon monoxide gas.
Pay attention to the warning labels. The engine exhaust system will
become heated during operation and remain hot immediately after the
engine is stopped.
TOXIC FUMES HAZARD. Running engines give off
carbon monoxide, an odourless poisonous gas
that can cause nausea, fainting, or death. Do
not start engine indoors or in an enclosed area,
even if the windows and doors are open.
DANGER TOXIQUE. Faire fonctionner un moteur dégage de
l’oxyde de carbone, un gaz inodore toxique qui peut
provoquer la nausée, évanouissement ou la mort. Ne
démarrer pas le moteur à l’intérieur ou dans une espace clos,
meme si les fenêtres et les portes sont ouvertes.
TM

2
Gasoline is a highly ammable and explosive liquid. Refuel in a well
ventilated area with the engine stopped.
When refueling the generator, keep it away from cigarettes, open ames,
smoke and/or sparks.
Use of gasoline with an ethanol content greater than 10% can damage
the engine and fuel system and will void the manufacturer’s warranty.
Place the generator at least 10 feet away from buildings or other
equipment during operation.
Run the generator on a level surface. Tilting the generator may result in
fuel spills.
Do not touch the spark plug while the engine is operating or shortly after
the engine has been shut down.
Know how to stop the generator quickly and understand operation of
all the controls. Never permit anyone to operate the generator without
proper instructions.
Keep children, pets and machinery with rotating parts away during
operation.
Do not operate the generator in rain or snow.
Do not allow any moisture to come in contact with the generator.
1.2 AC SAFETY
WARNING!
Before connecting the generator to an electrical device or power cord:
Make sure that everything is in proper working order. Faulty devices or
power cords can lead to an electrical shock.
Turn off the generator immediately if the device begins to operate
abnormally. Then disconnect the device and investigate the problem.
Keep away from other electric cables or wires.
To prolong engine life, make sure that the combined load of your
devices does not exceed the rated running wattage of the generator.
When an extension cable is required, be sure to use a tough rubber
sheathed exible cable (according to IEC245 or equivalent standards).
The maximum length of the extension cable: 196 feet (60 meters) for
cable of 15.5 gauge (1.5mm2); 328 feet (100 meters) for cable of 13.25
gauge (2.5mm2).
Connections for standby power to a building’s electrical system must
be done by a qualied electrician and must comply with all applicable
laws and electrical codes. Improper connections may cause serious
BG i-SERIES

3
injuries to electrical workers during a power outage, and when the
utility power is restored, the generator may explode or cause res. The
generator shall be connected through transfer equipment that switches
all conductors other than the equipment grounding conductor. The
frame of the generator shall be connected to an approved grounding
electrode.
This unit is oating neutral. The generator (stator winding) is isolated
from the frame and from the AC receptacle ground pin.
Electrical devices that require a grounded receptacle pin connection will
not function if the receptacle ground pin is not functional.
1.3 MAINTENANCE SAFETY
WARNING!
After any maintenance is performed, wash hands immediately using
soap and clean water because repeated exposure to lubricant may
cause skin irritation.
Do not clean the lter element with ammable liquids like gasoline
because an explosion may occur.
Turn off the engine and allow the generator to cool down before
performing any maintenance. Failure to do so can cause severe
personal injury or death.
Always wear safety glasses when cleaning the generator set with air.
Do not clean the generator set with a pressure washer because it can
damage the generator set.
When working with batteries, ventilate the area, use safety glasses, do
not smoke. Always disconnect the negative rst and reconnect it last.
Use rubber gloves when coming into contact with engine oil.
Always stop the generator set before removing the oil ller cap.
Only qualied maintenance personnel with knowledge of fuels,
electricity, and machinery hazards should perform maintenance
procedures.
See Chapter 7.1 for maintenance schedule.
TM

4
1.4 OTHER SAFETY TIPS
WARNING!
To avoid breathing in poisonous carbon monoxide from the exhaust
gases, adequate ventilation should be provided, only operate the
generator outside and away from enclosed areas, windows, and doors.
If the generator set is stored outdoors, check all the electrical
components on the control panel before each use. Moisture can
damage the generator and can lead to an electric shock.
Generators vibrate in normal use. During and after the use of the
generator, inspect the generator as well as extension cords and power
supply cords connected to it for damage resulting from vibration. Have
damaged items repaired or replaced as necessary. Do not use plugs or
cords that show signs of damage such as broken or cracked insulation
or damaged blades.
If you start to feel sick, dizzy, or weak after the generator has been
running, move to fresh air RIGHT AWAY. See a doctor. You could have
carbon monoxide poisoning.
TOXIC FUMES HAZARD. Running engines give off
carbon monoxide, an odourless poisonous gas
that can cause nausea, fainting, or death. Do
not start engine indoors or in an enclosed area,
even if the windows and doors are open.
DANGER TOXIQUE. Faire fonctionner un moteur dégage de
l’oxyde de carbone, un gaz inodore toxique qui peut
provoquer la nausée, évanouissement ou la mort. Ne
démarrer pas le moteur à l’intérieur ou dans une espace clos,
meme si les fenêtres et les portes sont ouvertes.
BG i-SERIES

5
2. LEARN ABOUT YOUR GENERATOR
This section will show you how to identify key parts of your generator. Going over
the terminology below will make sure we’re on the same page.
2.1 COMPONENT IDENTIFICATION
Air Filter
Cover
Fuel Cap
Oil
Dipstick
Control
Panel
Fuel Tank
Recoil Handle
Oil Drain
Bolt
Mufer/
Spark Arrester
Fuel Valve
Choke
TM

6
2.2 CONTROL PANEL
6
7
8
1 2 3
45
9
10
11 12 13 14
1. Ready to Use Indicator
2. Overload Indicator
3. Low Oil Indicator
4. Hour Meter
5. Power Switch
6. 120V 30A (TT-30 RV)
7. 120V 20A (5-20 R)
8. Parallel Ports
9. EcoMode
10. Ground Terminal
11. 20A AC Breaker
12. 27A AC Breaker
13. DC Breaker
14. 12V 8A DC Receptacle
BG i-SERIES

7
2.3 CONTROL FUNCTIONS
AC Circuit Breakers
While the generator is running, the breakers should be put in the ON
position.
If the current has exceeded its limits it will automatically pop out to the
OFF position. Reduce the electrical load on the generator and push the
button back to the ON position.
DC Circuit Breakers
The DC circuit breaker automatically shuts off when the charging circuit
is overloaded.
If the current has exceeded its limits the breaker will automatically pop
out to the OFF position. Reduce the electrical load on the generator and
push the button back to the ON position.
Hour Meter
Display shows total run time. Use this to perform maintenance at the
proper intervals according to the ‘Maintenance Schedule’ section of this
manual.
EcoMode (Economy Control Switch)
Turning EcoMode to ON is recommended for minimizing fuel
consumption. In this mode the engine will dynamically meet the demand
of the current electrical load and will automatically go into an idle state if
all electrical loads are disconnected.
Before connecting or removing a high load device to the generator, turn
EcoMode to OFF until that device has reached running power.
When EcoMode is OFF, the engine runs at full speed.
Ground Terminal
WARNING!
Before using the ground terminal consult a qualified electrician,
electrical inspector, or local agency having jurisdiction for local
laws and codes that apply to the intended use of the generator.
The ground terminal is connected to the non-current carrying metal
parts (such as the fuel tank), the frame, and the ground terminals of the
AC outlets. Floating Neutral.
TM

8
Low Oil Indicator Light
The oil alert system is designed to prevent engine damage caused by
an insufcient amount of oil in the crankcase. Before the oil level in the
crankcase reaches an unsafe limit, the oil alert system will automatically
shut down the engine (the battery power switch remains in the ON
position).
If the oil alert system shuts down the engine, the low oil indicator light
(red) will turn on. Check the engine oil level.
Power Switch
The two-way power switch starts and stops the unit.
ON: Switch must be in this position to recoil start.
STOP: Stops the engine.
Ready to Use and Overload Indicator
In normal operation, the green ready to use indicator light will remain on.
If the generator is overloaded (producing more than running wattage) or
a connected appliance has short-circuited, the output indicator light will
turn off and the overload indicator light will turn on.
2.4 MAKE SURE YOU HAVE EVERYTHING
Make sure your generator has everything listed in the table below.
Part Name Quantity
Inverter Generator 1
User Guide 1
Spark Plug Wrench 1
Oil Funnel 1
BG i-SERIES

9
3. PRE-OPERATION CHECK
Set the generator on a level surface and the power switch to STOP.
3.1 ADD OIL
1. Unscrew the oil dipstick.
2. Fill with fresh oil up to the maximum ll level on the dipstick.
3. Check the oil level by reinserting the dipstick without rethreading it.
Remove the dipstick and examine the oil level. If the oil level is at or below
the minimum oil level, continue lling the oil to the maximum oil level mark.
4. Reinsert the dipstick and tighten securely.
NOTE
SAE 10W-30 or SAE Synthetic 5W-30 is recommended for general use.
Use of synthetic oil does not change maintenance intervals.
Oil Capacity: 20 . oz. / 0.6 L
DO NOT OVERFILL.
Oil Cap
and Dipstick
Oil Funnel
Min Oil Level
Max Oil Level
Oil Capacity
20 . Oz / 600mL
Safe
Operating Range
0°C 10 20 30 40 50-10-20-30
20 32°F 40 60 80 100 120
°C
°F0-20
10W-40
10W-30
Synthetic 5W-30
5W-30
Effective Viscosity Range of Engine Oils
TM

10
3. PRE-OPERATION CHECK
Set the generator on a level surface and the power switch to STOP.
3.1 ADD OIL
1. Unscrew the oil dipstick.
2. Fill with fresh oil up to the maximum ll level on the dipstick.
3. Check the oil level by reinserting the dipstick without rethreading it.
Remove the dipstick and examine the oil level. If the oil level is at or below
the minimum oil level, continue lling the oil to the maximum oil level mark.
4. Reinsert the dipstick and tighten securely.
NOTE
SAE 10W-30 or SAE Synthetic 5W-30 is recommended for general use.
Use of synthetic oil does not change maintenance intervals.
Oil Capacity: 20 . oz. / 0.6 L
DO NOT OVERFILL.
Oil Cap
and Dipstick
Oil Funnel
Min Oil Level
Max Oil Level
Oil Capacity
20 . Oz / 600mL
Safe
Operating Range
0°C 10 20 30 40 50-10-20-30
20 32°F 40 60 80 100 120
°C
°F0-20
10W-40
10W-30
Synthetic 5W-30
5W-30
Effective Viscosity Range of Engine Oils
NOTE
Do not tilt the generator when adding engine oil. This could result in
overlling and damage to the engine.
Use high quality 4-stroke engine oil, certied to meet or exceed API
standard SG, SF, SAE ratings with strong detergents. Using non-
detergent or 2-stroke oil could shorten the engine’s working life.
Do not mix different engine oils.
Handle and store the engine oil with care, avoid getting dirt or dust into
the engine oil.
Before the engine oil falls below the safety margin, the low oil alert
system will automatically shut off the engine. The low oil light will turn
on.
To avoid the inconvenience of unexpected engine shutoff, check the oil
level as often as possible.
BG i-SERIES

11
3.2 ADD FUEL
DANGER!
Gasoline is highly flammable and explosive under certain
conditions. Refuel in a well-ventilated area with the engine
stopped. Do not smoke or allow open flames or sparks in the
area where the generator is being refueled or where gasoline
is stored. Do not overfill the tank. Be careful not to spill fuel
when refueling. Wipe up any spilled gasoline and let the area dry
before starting the engine.
Gasoline substitutes such as gasohol are not recommended.
They may be harmful to the fuel system components.
NOTE
Always place the generator on level ground and in a well ventilated area
when lling the fuel tank
Add fuel only to the red maximum ll ring on the fuel screen lter visible
in the ller neck.
Use of gasoline with an ethanol content greater than 10% can damage
the engine and the fuel system and will void the manufacturer’s
warranty.
Only use unleaded gasoline (Octane 85 or higher).
Never use stale or contaminated gasoline, or an oil/gasoline mixture.
Avoid getting dirt or water into the fuel tank.
Do not use a mixture of gasoline containing methanol. This will cause
serious damage to the engine.
Fuel Cap Fuel Cap
Maximum
Fill Ring
Screen Filter
Fuel Capacity
1.8 gal. / 7L
Maximum Fuel Level
TM

12
3.3 CHECK THE AIR FILTER
Examine the air lter before your rst use. Check the maintenance section for a
complete cleaning guide.
1. Unscrew the air lter cover and remove the lter.
2. Clean the foam air lter with soap and water or solvent and squeeze dry (do
not wring out).
3. Soak in clean engine oil.
4. Squeeze (do not wring) out all excess oil and reinstall. Replace the lter if it
is damaged.
NOTE
Running the engine without the air lter or a dirty air lter will quickly
degrade the engine.
Air Filter
BG i-SERIES

13
4. STARTING THE ENGINE
DANGER!
Using a generator indoors WILL KILL YOU IN MINUTES.
Generator exhaust contains high levels of carbon monoxide
(CO), a poisonous gas you cannot see or smell. If you can smell
the generator exhaust you are breathing CO. Even if you cannot
smell the exhaust, you could be breathing CO.
NEVER use a generator inside a home, garage, crawlspace, or
other partly enclosed area, deadly levels of carbon monoxide
can build up in these areas. Using a fan or opening windows and
doors will NOT supply enough fresh air.
ONLY use a generator outdoors and far away from open windows,
doors, and vents. These openings can pull in generator exhaust.
Even when you use a generator correctly, CO may leak into the
home. ALWAYS use a CO alarm in your home.
If you start to feel sick, dizzy, or weak after the generator has
been running, move to fresh air RIGHT AWAY and seek medical
attention. You could have carbon monoxide poisoning. Never
run the generator in an enclosed or even partially enclosed area
where people may be present.
TOXIC FUMES HAZARD. Running engines give off
carbon monoxide, an odourless poisonous gas
that can cause nausea, fainting, or death. Do
not start engine indoors or in an enclosed area,
even if the windows and doors are open.
DANGER TOXIQUE. Faire fonctionner un moteur dégage de
l’oxyde de carbone, un gaz inodore toxique qui peut
provoquer la nausée, évanouissement ou la mort. Ne
démarrer pas le moteur à l’intérieur ou dans une espace clos,
meme si les fenêtres et les portes sont ouvertes.
TM